Mechanical Engineering

Kais takes an overall approach in our design, leveraging our knowledge not only of battery packs but also battery cells, material, and software to design for perfection right down to the tiniest detail.

Ingress Protection
Phase-change Materials
Current Density Management
Ergonomics
Power Connectors
Cell Holder Optimization

MECHANICAL DESIGN
IN THE DETAILS

Lithium-ion battery cells are very delicate products that require very careful handling and meticulous design across every component, even the most minuscule flaw in the pack will steadily build up, breaking cell consistency with each use, and resulting in irreversible damage to the battery health and performance. That’s why Kais takes an overall approach in our design, leveraging our knowledge not only of battery packs but also battery cells, material, and software to design for perfection right down to the tiniest detail.

PREVENTION BY DESIGN

INGRESS PROTECTION

When it comes to ingress protection, there are no perfect materials,
only the perfect material solution.

The essential know-how of designing for impervious ingress protection is the experience working with most IP materials, understanding the demands required by different products and application scenarios. Accumulated and consolidated through decades of industry experience and persistent testing, Kais Power has developed a comprehensive library and database of every ingress protection material on the market. Our veteran engineers are equipped with the best material knowledge to design for the most challenging environment and operating conditions. But we are not satisfied with only using the existing material, the Kais material testing and analysis lab are constantly researching and validating the performance of new and existing IP materials.

3 MAJOR CATEGORIES

SEALANT FOAM TAPE RUBBER SEALED LOOP PARYLENE COATING

BUS BAR DESIGN

CURRENT DENSITY MANAGEMENT

One of the most common design flaws in battery packs is to overlook the actual working condition of each cell and assume they are consistent. In our Bus Bar Design, we want to make sure that the current density remains constant across every cell in the module to maximize the life cycle of the battery. We consider the traveling path of the current, analyze its distance and medium to ensure the operating condition of each cell will keep consistency over thousands of uses.

DESIGNED FOR OPTIMAL END-USER EXPERIENCE

ERGONOMICS

Kais strives to make the impact of our superior design felt by the end-user. All the KAIS engineers are trained to adhere to ergonomics principles to maximize the end-user experience.

For example, we understand that battery packs are heavy objects, so we endeavor to lighten the load and maximize the lifting comfort of our battery packs by adjusting grip position according to the actual center of gravity to ensure the batteries are well-balanced and easy to move around with. We also developed widen & round grip and patterned hilt designed and optimized according to ergonomics simulation to maximize comfort and enhance handling experience.

GRIP DESIGN

Widen & round grip and patterned hilt designed and optimized according to ergonomics simulation to maximize comfort and enhance handling experience.

LIFTING COMFORT

Grip position adjusted according to the actual center of gravity to ensure the balance of lifting.

BUILT TO LAST

POWER CONNECTOR

Power connectors only take up 1% of the BOM cost, but it causes 10% of all battery failure.

Design flaws in power connectors will increase temperature rise, which will eventually lead to a meltdown of functioning components in the connector, causing the connector to malfunction and short-circuit. That’s why Kais takes special care in designing customized power connectors. Whether our customer needs a modification of standard off-the-shelf connectors or customized connectors, our engineers can provide customized solutions optimized with the best of our experience and knowledge.

Kais is fully equipped to test our design. All of Kais connectors are tested through a series of tests, including temperature endurance test, structural test, Salt spray test, insertion force test up to 10,000 times, etc.

STRONG AND DURABLE

CELL HOLDER OPTIMIZATION

Cell holders are the pillars that hold up a battery’s internal structure

That’s why its design is crucial to applications that require strong structural strength to protect against consistent impact, such as power tools or e-mobility applications. At Kais, we take a systematic approach in making cell holders: for materials, Kais requires all incoming material to satisfy UL94V0, REACH, RoHS 2.0 standards, as well as our own durability tests. For design, we utilize our precision simulation tools and consider the topology as well as the strength of material to optimize heat dissipation and the ability of the battery pack to absorb impact. We also consider the ease of installation, repair, and maintenance into our design to facilitate after-sales services.